Drive Shaft Torsion Test System Design
A client in the automotive industry had existing equipment for performing torsion tests on its drive shaft components. The client had an urgent need for a software application to perform the tests and generate data in time for a trade show presentation. Re:Build Optimation had the ability to come in and quickly get the project done in the time frame they required.
Design & Build High Pressure Mixed Gas Test System
An undersea cable company was looking for a firm to design and build a high-pressure mixed gas system to pressure test the various undersea components they manufacture. These components are installed into high-pressure vessels and externally gas-pressurized to 2 main pressure setpoints – 15,000 psig or 5,000 psig, and these components are required to pass both a pressure test and a trace gas leak test. They called on Re:Build Optimation to design, build, test, and install the system at their site.
Design & Build Fuel Cell Test Systems
Fuel cells are a new clean energy technology that can be used in a wide range of applications, including transportation, material handling, and emergency backup power generation. Many industries today are relying on vehicles powered by Fuel Cell Engines, where hydrogen is used to generate power by a chemical reaction, rather than the typical gasoline-powered combustion engine. This new alternative energy engine produces electricity to drive them, with only water and heat as the waste products – a considerable improvement over the greenhouse gas carbon dioxide (CO2) produced from traditional gasoline-powered vehicles (and per various scientific studies, did you know that all that additional CO2 emitted over the past 100 yrs has warmed the planet by 50%?).
Enter a new technology looking to replace the traditional gasoline-powered engine – a Fuel Cell.
A prominent Fuel Cell Manufacturing Co was looking for a firm to do final design/build of a new Fuel Cell Test System to test their products under various utility load conditions. The Client was developing Fuel Cell Engines primarily for the material handling and transportation industries for the ever-growing need of Fuel Cell powered equipment and vehicles. As part of their development process, an intensive verification program was planned to ensure their new flagship products can satisfy customer requirements for performance, safety and reliability. The completion of this verification program depended on the Client expanding its current testing infrastructure for larger sized engine products.
For this reason, the Client partnered with Re:Build Optimation to design, fabricate, test, and deliver a fully functional test system to satisfy the program’s requirements.
Conveyance and Roller Design Consulting
A client manufacturing consumer products contacted Re:Build Optimation for web handling consulting. The client’s operation was experiencing significant quality issues and waste generation which was a threat to their production feasibility. The problem was described as the inability of their current equipment to convey sensitive web without inducing roller contact defects such as web digs and web scratches.
Control System Design
Synergy is a leading manufacturer and supplier of flavors, extracts, and essences for the food and beverage industries.
Synergy was in the process of relocating its manufacturing from an existing facility in Wauconda Illinois to a new and larger facility to accommodate growth. As part of this process, Re:Build Optimation was hired to assist in the development of the project design documents for the bidding process.
Turnkey Coating Skid
A manufacturer of nanomaterials for composites had a product that needed to be produced without being touched or disturbed. The company’s product is manufactured continuously on a roll-to-roll web. The end result is a coated wound roll of a delicate powder, which if touched would abrade off and release into the air, becoming a health concern. The manufacturer came to Re:Build Optimation to help solve the issue of how to produce the rolls without damaging the coating.
Catalyst Reactor Test System
Fuel cells are a fast-growing market, and that means there can be quality issues with incoming material, especially with the supply chain disruptions that have been experienced in the last couple years. For one client, using catalyst material that is out of spec can cost them millions of dollars for each unit produced. To help prevent this major disruption and cost, we partnered with the client to create a semi-automated test system that will safely operate at very high temperatures with flammable gas mixtures. The customized test system will be used to ensure the catalyst used in their finished product passes their strict specifications.
Batch Control System Replacement
A client in the food industry needed to replace a legacy ABB MOD300 distributed control system without stopping production for longer than 12 days.
Automated Production Line
Our customer’s patented technology is to adhere a dry food/beverage on a substrate. Their first product is a functional beverage printed on a biodegradable cup. The application is a very efficient way to sell and ship products that previously contained liquid in a liquidless format. The liquid is added at the point of use, this reduces shipping costs and the impact on the environment by requiring less transportation effort to ship the same amount of products. The customer has been producing small batches of their products and selling direct to the consumer. They came to Optimation to ramp up production by having us design and build an Automated Production Line.
